Applicator assembly for application of adhesives, sealants and coatings

ABSTRACT

A melter, mixer and applicator system for applying coating or sealing compositions is disclosed. A diesel engine provides the motive force necessary to operate many of the components of the system. A tank surrounded by an internal heating system is provided for melting a first material. An insulated cabinet is provided and heated from heat generated by the internal heating system. The plumbing configuration is disposed within the heated cabinet for mixing the material heated within the tank with an additional material fed to the plumbing configuration by a proportioner pump. The output of this mixture serves as one of the inputs to the applicator. The other input to the applicator is another material fed directly from the proportioner pump. The proportioner, preferably provides the two materials running through it in a predetermined ratio amount with respect to each other.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to applicators for the handling and applicationof materials, and particularly to an applicator assembly for use in thein situ generation, preparation, mixing and application of compositionsfor use as coatings, sealants, adhesives, etc. The compositions can beused in many applications, including, but not limited to, roofing,coverings, and construction waterproofing applications.

2. Description of Related Art

Due to the nature of the materials used in forming bituminouspolyurethane interpenetrating elastomeric network compositions, as wellas other compositions, specialized equipment is required to prepare, mixand apply the materials to form the composition. This equipment must beportable so as to allow it to be taken to the job site or any otherdesignated area.

Various applicators and devices for preparing materials, such asasphalt, are known. However, the prior art fails to provide for anapplicator system, which, in addition to preparing asphalt, also permitsmixing of the asphalt with other materials to form a composition, whichis created just prior to application or in situ. It is therefore to theeffective resolution of the shortcomings of the prior art that thepresent invention is directed.

BRIEF SUMMARY OF THE INVENTION

A melter, mixer and applicator system for applying coating or sealingcompositions, or other compositions or material(s) is provided by thepresent invention. The various components of the applicator system aresecurely attached or mounted onto a frame for ease in transportation ofthe system. An internal combustion engine, such as a diesel engine, canbe mounted on the frame and provides the motive force necessary tooperate many or all of the functions and components of the system.

A tank surrounded by an internal heating system is provided for meltinga first material, such as asphalt. An insulated cabinet is provided andheated from heat generated by the internal heating system. The plumbingconfiguration for the system is disposed within the heated cabinet formixing the material heated within the tank with an additional materialfed to the plumbing configuration by a proportioner pump. The output ofthis mixture serves, through a heated hose, as one of the inputs to theapplicator, which is preferably a plural component spray gun, thoughsuch is not considered limiting. The other input to the applicator isanother material fed directly from the proportioner pump. Theproportioner, preferably provides the two materials running through itin a predetermined ratio amount with respect to each other. A pre-heaterassembly can be disposed within the heated cabinet for heating thematerial fed from the proportioner prior to its mixing with the materialfrom the tank.

The cabinet is preferably provided with an access door to provide easyaccess to the interior area of the cabinet and the various componentscontained within.

Storage racks can be provided along the sides of the system to store orhouse the various hoses used with the system during transit or when thesystem is not in use. The vertical height of the racks can be positionedsuch that the fenders covering the wheels can also be used to providedsupport to the hoses stored within the racks.

In use, a first material is heated in the tank. Once the material hasreached a sufficient temperature, a pump will begin to recirculate ordraw out the liquefied material and send such material to a static mixerfor mixing with a second material which has been supplied in apredetermined portion from the proportioner. The mixed material isforwarded through a heated hose as a first input to the user operatedapplicator (e.g. spray gun). A second input to the applicator isprovided directly from proportioner in its predetermined portion. Theheated hose is coupled or connected to an electrical outlet powered by agenerator. Through the use of a trigger on the applicator, the operatoropens a valve in the applicator, to allow the combined material fromboth inlets to flow through onto the desired substrate or surface. Thus,the applicator system provides a novel pumping, metering, mixing, andspraying system.

Thus, the invention discloses a melter, mixer and applicator system forapplying coating or sealing compositions. An internal combustion engine,such as a diesel engine, is used to provide the motive force necessaryto operate many or all of the components of the system. A tanksurrounded by an internal heating system is provided for melting a firstmaterial, such as asphalt. An insulated cabinet is provided and heatedfrom heat generated by the internal heating system. The plumbingconfiguration for the system is disposed within the heated cabinet formixing the material heated within the tank with an additional materialfed to the plumbing configuration by a proportioner pump. The output ofthis mixture serves, through a heated hose, as one of the inputs to theapplicator, which is preferably a plural component spray gun. The otherinput to the applicator is another material fed directly from theproportioner pump. The proportioner, preferably provides the twomaterials running through it in a predetermined ratio amount withrespect to each other. A pre-heater assembly can be disposed within theheated cabinet for heating the material fed from the proportioner priorto its mixing with the material from the tank.

Accordingly, it is an object of the present invention is to provide anovel pumping, metering, mixing, and spraying system for plural materialcompositions.

It is another object of the present invention to provide a system forpreparing plural material compositions at or near the site ofapplication.

In accordance with these and other objects, which will become apparenthereinafter, the instant invention will now be described with particularreference to the accompanying drawing.

BRIEF DESCRIPTION OF THE FIGURE

FIG. 1 is a perspective view of the present invention applicator system;

FIG. 2 is a right side elevational view of the applicator system of FIG.1;

FIG. 3 is a left side elevational view of the applicator system of FIG.1;

FIG. 4 is a top view of the applicator system of FIG. 1;

FIG. 5 is a back elevational view of the applicator system of FIG. 1;

FIG. 6 is a front elevational view of the applicator system of FIG. 1;

FIG. 7 is a further perspective view of the applicator system of thepresent invention; and

FIG. 8 is a perspective view of preferred plumbing configuration for theapplicator system of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

As seen in the drawings, a melter, mixer and applicator system forapplying coating or sealing compositions, or other compositions ormaterial(s), is illustrated and generally designated as referencenumeral 10. In the most preferred form, applicator system 10 can betransported on a frame 12 that is towable behind a vehicle.Alternatively, the various components of applicator system 10 can beprovided on a truck, such as, but not limited to, a flat bed truck.Where a frame 12 is provided, frame 12 can be provided with aconventional trailer hitch 14, along with wheels 16 and fenders 17covering the wheels, to form a trailer for applicator system 10. Thevarious components of applicator system 10 are securely attached ormounted onto frame 12 such that it may readily be towed or transportedto any required designation.

An internal combustion engine 18, such as, but not limited to, a dieselengine, can be mounted on frame 12 and provides the motive forcenecessary to operate many of the functions of applicator system 10,which will be discussed further below. Engine 18 preferably runs aconventional generator for generating electrical current, such as forelectricity to one or more heated hoses used in conjunction withapplicator system 10. A hydraulic pump and/or compressor 25 can also bedriven by engine 18. A control box can be coupled with engine and servesto control engine 18, the hydraulic pump and/or compressor 25. Anignition system can be provided for starting engine 18. Engine 18,compressor 25, the generator and other components can be containedwithin a pivotable enclosure 19. Enclosure 19 can be noise insulated andlockable for security purposes. Additionally, a cooling fan 21 can alsobe provided for cooling engine 18. A muffler 30, such as a cowl muffler,can also be provided with engine 18. Engine 18 can be joined to frame 12by rubber engine mounts to prevent vibration transfer. Engine 18 ispreferably protected by a conventional integral engine management systemincluding an alternator, oil pressure and water temperature shutdowns.

A tank 26 is provided, having one or more access covers 28. Tank 26 is arelatively large kettle made of a suitably strong material, which willwithstand the repeated heating of various volatile materials as well assupporting the weight of a large volume of these materials. Preferably,surrounding tank 26 is an internal heating system. The heating systemincludes one or more burners which are supplied with a fuel, such asdiesel or liquid propane gas. A fuel supply container 34 is provided onframe 12 to deliver fuel to the burner. The burner is directed into andin communication with a heating chamber. A fuel gauge can be providedfor easy determination of the fuel level within container 34. Theheating chamber preferably essentially surrounds tank 26 on all but itsupper surface. Heat directed into the heating chamber from the burnereffectively and efficiently heats tank 26 and its contents. A burnercontrol can be provided to control the operation of the burner. Asuitable tank and heating system is disclosed in U.S. Pat. No.6,109,826, the disclosure of which is incorporated by reference.

A chimney 40 can form part of the heating system and is coupled to andin communication with the heating chamber. Chimney 40 vents thebyproducts from the combustion of the burner out of the heating chamberin a controlled fashion. Chimney 40 may also be fluidly connected to andin communication with tank 26 via a chimney tube 42. As chimney 40 ventsfumes from the combustion, a draw can be created which siphons off anygaseous material which may be trapped in an upper portion of tank 26,thus directing it from tank 26, through chimney tube 42 and out throughchimney 40. Due to the elevated temperature of the fumes venting throughchimney 40, the gaseous material siphoned from tank 26 is burned orotherwise consumed in chimney 40 so that the exhaust from chimney 40 canbe relatively clean and odorless. However, a separate burner unit mayalso be incorporated into the chimney tube 42 for such purposes. Thisburner unit burns the byproducts produced in tank 26, thus purifying, tosome extent, the emissions from tank 26.

Applicator system 10 also includes an insulated cabinet 44 adjacent toheating system 30. Cabinet 44 is a relatively large, empty chamber,which can be selectively heated by the burner within the heatingchamber. Cabinet 44 houses a piping/hose configuration 120 for mixingthe material heated and contained within tank 26 with an additionalmaterial fed through a wall of cabinet 44 by a pipe or hose 82. Heatedcabinet 44 helps to prevent solidification of material flowing throughplumbing configuration 120.

When heating cabinet 44, a vent/passageway 46 is at least partiallyopened to provide communication between a portion of the heating chamberand the interior of cabinet 44 to provide residual tank or kettle heatto heat up the interior of cabinet 44, pump assembly 60 and pre-heaterassembly 80. Once vent 46 is at least partially opened, heat flows fromthe burner, through the heating chamber and into cabinet 44. While anyappropriate type of control may be employed, a control arm attached to avent cover portion or gate door 49 is preferably provided and connectedapproximate vent 46. By controlling the amount that vent 46 is opened bythe positioning of gate door 49, the operator can effectively control orregulate the amount of heat that is allowed to enter cabinet 44 throughvent 46 from the burner. The control arm preferably extends out throughan opening in the top of cabinet 44. When the control arm is raised, itfurther opens vent 46. Where vent 46 is closed, no significant amount ofheat is allowed to enter cabinet 44 from the heating chamber. To placevent 46 in its most opened position, the control arm is raised. Theamount vent 46 is opened/closed is adjustable by moving the control armto dispose cover portion 49 in various positions over vent 46. Thecontrol arm can be held in a desired position by a cooperation of one ormore control arm teeth mating with an upper surface of cabinet 44.

In use, access cover 28 is opened and the desired material(s), such as abituminous material or asphalt, is placed within tank 26. The burner 32is ignited and heats tank 26 and its contents to a temperaturesufficient to liquefy the material. For asphalt, this will usuallyrequire a temperature range between about 250°-500° F. (120°-240° C.).

Concurrently, an agitator can be located within tank 26 and constantlymixes the heated material(s). The agitator helps to assure an evendistribution of the material and to prevent pockets of solidifiedmaterial from forming inside tank 26. The agitator can be coupled to ahydraulic motor, which is in turn coupled to a hydraulic pump powered byengine 18. A shutoff system can be provided with the agitator toautomatically turn off the agitator when access door 28 is opened.Raising door 28 can terminate hydraulic flow to the agitator motor tostop the mixing process. As the material is withdrawn from tank 26, morematerial can be added, if desired, within tank 26 so that a sufficientsupply of material is maintained. The agitator can be a bidirectionalhydraulically driven, vertical agitator with tow horizontal paddles andvertical risers.

During the course of heating the materials, various noxious fumes andsmoke can be created. Thus, access cover 28 is generally kept closed tomaintain the efficiency of the heating process. Therefore, any createdfumes and smoke may be trapped within tank 26. In order to maintain asufficient supply of material, an operator may inspect tank 26 andvisually determine the level and/or condition of the material. Tofacilitate this visual inspection, chimney 40 of heating chamber 38 canbe in communication with tank 26 via chimney tube 42 at a point abovethe level of the mixture/material within tank 26. As discussed above,any fumes and smoke will be drawn out of tank 26 and vented throughchimney 40. Without the use of chimney tube 42, cover 28 must be openedfor a sufficient time period to allow the fumes and smoke to clear.Leaving cover 28 open for any extended time period may permit a largeamount of heat to escape, thus seriously reducing the efficiency of theheating system. Therefore, chimney tube 42 also serves to reduce theamount of time access cover 28 must remain open, which increases theefficiency of the heating system.

FIG. 8 best illustrates a plumbing configuration 120 for the presentinvention. For purposes of illustration, the sidewalls of heated cabinet40 have been removed in this Figure and in FIG. 7. A recirculating pumpassembly 60 and inlet valve 62 can be located within cabinet 44. Pumpassembly 60 can include a helical gear pump coupled to a hydraulicmotor, though such is not considered limiting. An inflow pipe not shownis coupled between inlet valve 62 and tank 26 and provides communicationbetween such components. Pump 60 is conventional and is used to pump thematerial (e.g. bituminous material, asphalt, e.g.) from tank 26. Pump 60can be also be used to circulate cleaning material (i.e. mineralspirits) for cleaning or flushing various portions of plumbingconfiguration 120 for maintenance purposes. Pump 60 can be eithercontinuously or systematically actuated to draw the liquefied materialfrom tank 26, through pump 60 and then, in some instances, deliver it atleast partially back to tank 26 through return pipe/hose 63. This servesto bring heated material to pump 60, which helps to heat pump 60 andalso prevents any of the liquefied material from settling within pump60. When the operator desires to use the applicator (i.e. sprayer, spraygun, etc.), this recirculation is minimized thus directing a majority ofthe fluid flow through pump 60 into static mixer 65, where it is mixedwith a second material (i.e. polyol, etc.) prior to delivery to theapplicator.

Inlet valve 62 can act as a “shut of” valve and allows material to flowfrom tank 26 to pump 60. The inflow pipe is preferably positioned at ornear the bottom of tank 26 to enable the pressure generated by thevolume of material disposed within tank 26 to assist pump 60 in drawingliquefied material through inflow pipe 62. The inflow pipe can bepositioned at an angle. Coupled to the outlet line/pipe 66 of pump 60 isa junction 68 which preferably joins several components includingmaterial circulation (by-pass) valve 70, material check valve/mixingblock 74 and material thermometer assembly 76. Though not shown apressure assembly, including a pressure gauge, can also be includedwithin the configuration.

By-pass valve 70 allows at least some of the material received from tank26 to be pumped back to tank 26 through return pipe, hose or tube 63.Outflow pipe 63 is a return line that leads back to tank 26. Valve 70can be of a differential type to allows the operator to set the flowrate of material returning back to tank 26. When the static mixer 65 isoccluded (either because outlet valve 110 is closed and/or a valve ofthe applicator (e.g. spray gun) of a hose attached to valve 110 isclosed), pump 60 can be placed in a recirculation mode. In this mode,pump 60 draws liquefied material out of tank 26 through the inflow pipeand returns it to tank 26 through outflow pipe or hose 63. Therecirculation can be generally continuous or intermittent. The recurrentflow of the liquefied material through pump 60 prevents any of thematerial from settling long enough to cool and solidify during normaloperation. However, the heated insulated cabinet 44 also helps toprevent the material from cooling and solidifying.

Valve/block 74 serves as the entry point from the material receivedthrough pre-heater assembly 80 and hose 82. This material is added tothe material received from tank 26 for mixing within static mixer 65.Valve/block 74 also serves to prevent any material received through hose82 from entering pump 60. Thus, the inlets to valve/block 74 are thematerial flowing through hose 82 and the material flowing from pump 60which are both fed from valve/block 74 to static mixer 65. Static mixer65 serves as the supply line, through valve 110, to the applicator forthe mixed material. Thermometer assembly 76 includes a pipe/line 78attached at one end to junction 68 and at its opposite end tothermometer gauge 79. Gauge 79 can be located within cabinet 44 orprotrude through an opening in cabinet 44. Where protruding through, theopening can be sealed to help prevent heat from escaping. Gauge 79indicates the temperature of the material from pump 60 as it flows. Thepressure gauge, if provided, indicates the pressure of the material frompump 60 as it flows.

A material PSI relief valve 81 can be provided and connected to be incommunication with junction 68. Relief valve 81 allows material fromtank 26 to flow back to tank 26 if the heated hose incurs backpressure.Various filters or strainers can be provided within the plumbingconfiguration, including, but not limited to, filter/strainer 85 whichfilters material from tank 26 before it reaches pump 60.

A check valve 83 is preferably in communication with hose 82 and servesto prevent any material received from tank 26 from entering hose line82. Hose 82 is preferably connected at an opposite end to pre-heater 80.Pre-heater 80 heats material flowing in from proportioner 100 viahose/line 102 which is attached at one end to an outlet of proportioner100 and at an opposite end to the inlet of proportioner 100. Preferably,pre-heater 80 consist of a series of tubes 72 that are in communicationwith each other. Pre-heater 80 is preferably mounted to a sidewallwithin the interior of cabinet 44 by one or more bracket assemblies 81or other conventional attachment devices. Tubes 72 are preferablyconstructed from steel, metal or any other material capable of heatingto a desired temperature. Tubes 72 preferably heat radiantly from heatentering into cabinet 44 through vent 46. The first end of hose 82 isconnected to the outlet of pre-heater assembly 80. It should be notedthat hoses, piping and/or tubing can be used interchangeably for thevarious components of plumbing configuration 120. Additionally, system10 is provided with conventional metal, aluminum, plastic and/orplumbing connectors for connecting the various hoses, pipes and tubes ofand used with the present invention.

Proportioner 100 is used to provide or pump in predetermined ratios ofcertain materials for the desired composition. Proportioner 100 ispowered by compressor 25, acts as a pump and is provided with an inletarea 102 and an outlet area 104. A first conventional hose or otherelongated tube (not shown) is preferably connected at a first end to afirst connector of inlet area 102 and at a second end to a first drum orother receptacle containing a first material, such as, but not limitedto, a polyol. A second conventional hose or other elongated tube (notshown) is preferably connected at a first end to a second connector ofinlet area 102 and at a second end to a second drum or other receptaclecontaining a second material, such as, but not limited to, an isocyanateor other hardener. The pump component of proportioner 100 draws thematerials in the desired set or programmed ratio amount through theirrespective hoses from their respective drums. The present invention isnot limited to any specific ratio setting for proportioner 100 and allvarious combinations (e.g. 4 to 1, 3 to 1, etc.) can be used and areconsidered within the scope of the invention.

The desired ratio of the first material is fed to the inlet ofpre-heater assembly 80 from proportioner 100 through hose 102, whichextends through an opening in cabinet 44. The opening is preferablysealed to help prevent heat from escaping from within cabinet. Hose 102is connected at a first end to a first connector of outlet area 104 andat a second end to the inlet of pre-heater 80. The desired ratio of thesecond material is fed as an input to the applicator (e.g. spray gun) bya conventional hose. The hose is connected at a first end to a secondconnector of outlet area 104 and at a second end to a first inletattachment point of the applicator.

As a second input to the applicator, a heated hose is attached at afirst end to an outlet valve 110, which preferably protrudes out ofcabinet 44 and is in communication with and connected or coupled tostatic tube 65. A second end of the heated hose is connected at a secondinlet attachment point of the applicator. A third inlet attachment pointcan be provided on the applicator for attachment of a solvent flush linewhich is attached at an opposite end to a receptacle containing cleaningmaterial such as mineral spirits. The flush line is provided forcleaning the applicator.

The hose used to deliver the material mix from outlet valve 110 to theapplicator (e.g. spray gun, etc.) is preferably heated and can be anyconventional type of heated hose. One embodiment can include a heatingelement, which surrounds the hose and a heating unit, which powers andcontrols the heating element. The heated hose can be heated by a sheath,which surrounds the hose. As an example, a heating element may be woveninto the sheath, and as it is energized, it generates thermal energy,which is transferred through the sheath to the hose. In one preferredembodiment, the heating element can be an electrical coil, which can beenergized by plugging into an electrical outlet of a junction boxpowered by the generator (i.e. receives electric current from thegenerator). The heating element can generate an electrical currentthrough a wire (or wires) that is coiled about the outer circumferenceof the hose. The hose is preferably heated right up to its connectionwith coupling/outlet valve 110 on one end and the applicator on theother end. However, any appropriate combination of a heating element andheating unit, including but not limited to, electric coils, heated fluidor hydraulic coils, heated air coils, or any type of convective orconductive heating element may be utilized to heat the hoses and all areconsidered within the scope of the invention.

One type of applicator which can be used to spray the combination of themixed materials from static mixer/tube 65 and from the hose attached tothe second connection in outlet area 104 of proportioner 100 is a spraygun such as, but not limited to, the Model 43P Airless Gun manufacturedby the Binks company. This spray gun provides a plural component (sprayand/or pour) dispensing device using a static mixing principle. The gunis provided with internal orifices and spray patterns are by nozzleselection. The output of the spray gun is dependent upon nozzle andimpingement orifices in conjunction with applied fluid pressures. Thegun is operated by trigger and operates under high pressure (i.e.approximately up to 3500 pounds per square inch).

The hose connected to outlet valve 110 can be through a releasable,rotatable connection. Since the heated hose need not be placed intocabinet 44, the connection can occur outside of cabinet 44 so that amaximum length of the heated hose is available to perform the desiredfunction. The spray gun connected at the opposite end of the hose canalso include an adjustable valve that allows the operator to control theflow of the mixed material received from static mixer 65 and the secondoutlet connection of proportioner 100. The spray gun can be providedwith a handle so the operator does not have to directly contact the hoseitself.

Pump 60 is preferably of the recirculating type though such is notconsidered limiting. In this preferred form, material or fluid can becontinuously moved through valve 70, and mixed material from staticmixer 65 selectively moved through valve 110, the hose connected atvalve 110, and any valve provided with the applicator when each is setto an open condition or position. Valve 70 can be adjusted so thatadequate pressure will be supplied to the hose attached to valve 110,when desired. Alternatively, through a switch or lever, therecirculation capability of pump 60 can be turned off and/or valve 70closed, such that the material from tank 26 is only sent to static mixer65 for mixing with the material received through hose 82.

Cabinet 44 is preferably provided with an access door 98 to provide easyaccess to the interior area of cabinet 44 and the various componentscontained within. Because contents flowing through pipe/hoseconfiguration 120 should be heated, the location of the configuration isdisposed within heated and insulated cabinet 44.

Storage racks or braces 160 can be provided along the sides of system 10to store or house the various hoses used with the system during transitor when the system is not in use. The vertical height of racks 160 canbe positioned such that the fenders 17 covering wheels 16 attached toframe 12 can also be used to provided support to the hoses stored withinracks 160. System 10 can be provided with various meters, gauges,controls, thermometers, etc. to monitor the various components andmaterials at various locations within system 10 and/or operate thecomponents of system 10. A control box 180, which can be powered by thegenerator, can provide at least some of the controls for operatingsystem 10 and/or electrical outlets for energizing the heated hose(s).

In one use of application system 10 according to the teachings of thepresent invention, a first material is heated in tank 26. Once thematerial has reached a sufficient temperature, pump 60 will begin torecirculate or draw out the liquefied material and send such material tostatic mixer 65 for mixing with a second material which has beensupplied in a predetermined portion from proportioner 100. The mixedmaterial is forwarded through a heated hose as a first input to the useroperated applicator (e.g. spray gun). A second input to the applicatoris provided directly from proportioner in its predetermined portion. Theheated hose is coupled or connected to an electrical outlet powered bythe generator which is run by engine 18 so that electrical current issupplied to the heating element surrounding the hose.

Through the use of a trigger on the applicator, the operator opens avalve in the applicator, to allow the combined material from both inletsto flow through onto the desired substrate or surface. During periods ofnon-use (i.e., between applications or while moving to a new location),the operator may simply leave the hose unattended, as the heating coilssurrounding the hose will prevent solidification of the combinedmaterial. Alternatively, the first and second inlets to the applicatorcan be closed and the third inlet (solvent line), associated with acleaning material, can be opened to clean the applicator. For extendedperiods of non-use, the various hoses are wrapped around system 10 inconjunction with storage racks 160.

When using application system 10 to create a rubber sealant membrane,the polyol can be the material fed through hose 82 to static mixer 65and the bituminous material is heated within tank 26 to its moltentemperature. Through plumbing configuration 120, these materials aremixed together in static mixer 65 to form a reagent mixture. Theisocyanate is the material fed to the applicator directly fromproportioner 100. The reagent mixture is carried separately from theisocyanate to the mixing head of the applicator by a heated hoseattached to outlet valve 110. At the mixing head, the reagent mixtureand isocyanate are mixed. The polyurethane prepolymer forms as thereagent material and isocyanate mix. These materials can be metered andare sprayed under pressure through a suitable spray apparatus, such as,but not limited to, the spray gun discussed above. Thus the threecomponents are mixed together immediately before spraying, and theresultant composition can be sprayed onto various different substrates.System 10 initiates an in situ polymerization reaction at the sprayingdevice by mixing the materials intensely so that a three-dimensional,semi-interpenetrating network molecular structure formation begins. Theproperties of the resulting three-dimensional matrix can be controlledby changing the formulation, such as by changing the ratio onproportioner 100. By increasing the proportion of cross-linking agentssuch as diisocyanate, the strength of the product is increased. Byreducing the proportions of cross-linking agents, the flexibility of thematerials can be increased. Thus, the system 10 provides a novelpumping, metering, mixing, and spraying system.

The heated hose can preferably run from anywhere between approximately0° F. and approximately 350° F., and preferably approximately 325° F.The temperature of tank 26 is preferably between approximately 0° F. andapproximately 500° F., and preferably approximately 340° F. Thetemperature of heated cabinet 44 is preferably approximately 300° F.None of these temperatures and ranges are considered limiting.Furthermore, system 10 is not intended for use for any single purposeand can be used for a variety of purposes and applications.Additionally, system 10 is not limited to the use of three separatematerials. Accordingly, system 10 can be used with a single materialeither fed from proportioner 100 or tank 26, two materials, threematerials, and other combinations, all are considered within the scopeof the invention. Additionally, system 10 is not limited to anyparticular types of materials.

It should be also recognized that many of the hoses used for system 10could also be tubing or rigid or flexible pipes or piping. Likewise manyof the pipes or piping could also be hoses. Thus, the invention is notlimited to any one specific type of fluid or material transporter anduse of words such at tubing, pipes, hoses, fluid or material lines,lines, etc. throughout the application and claims are considered to bebroadly interpreted to encompass all types of fluid or materialtransporters.

The instant invention that has been shown and described herein isconsidered to be the most practical and preferred embodiment. It isrecognized, however, that departures may be made therefrom within thescope of the invention and that obvious modifications will occur to aperson skilled in the art.

What is claimed is:
 1. An applicator system for melting, mixing andapplying a composition consisting of one or more materials, saidapplicator system comprising: a tank having a material receiving area;means for heating said tank to sufficiently melt a material disposedwithin the material receiving area; a cabinet receiving heat from saidmeans for heating, said tank externally located from said cabinet; meansfor removing melted material from said tank; means for supplying asecond material and a third material; means for mixing the secondmaterial with the melted material; and an applicator receiving the mixedsecond material and melted material from said means for mixing and thethird material from said means for supplying.
 2. The applicator systemof claim 1 wherein said applicator is a plural component spray gun. 3.The applicator system of claim 1 further including means for controllingthe amount of heat received within said cabinet.
 4. An applicator systemfor melting, mixing and applying a composition consisting of one or morematerials, said applicator system comprising: a tank having a materialreceiving area; a heating system surrounding a majority portion of saidtank to sufficiently melt a material disposed within the materialreceiving area; an insulated cabinet receiving heat from said means forheating; means for controlling the amount of heat received within saidinsulated cabinet; a pump and valve assembly in communication with saidtank, said pump removing melted material from said tank; a proportioner,said proportioner supplying a second material to the insulated cabinetand a third material; means for mixing the second material with themelted material; and an applicator receiving the mixed second materialand melted material from said means for mixing and the third materialfrom said means for supplying; wherein said proportioner providingsupplying the second material and the third material in a predeterminedratio with respect to each other.
 5. The applicator system of claim 1wherein said applicator is a plural component spray gun.
 6. Theapplicator system of claim 4 wherein said means for mixing comprises: apreheater disposed within said insulated cabinet, said preheater havingan inlet and an outlet, said preheater communicating with saidproportioner through a first line connected between the inlet of saidpreheater and a first outlet of said proportioner; a mixing block incommunication with said preheater through a second line connectedbetween the outlet of said preheater and an inlet of said mixing block,said mixing block also in communication with said means for removing,said mixing block receiving and mixing the melted material received fromsaid mean for removing and the second material received through saidpreheater; and a static mixer in communication with an outlet of saidmixing block for transporting the mixed material; wherein said pump andvalve assembly, said static mixer, said mixing block and said preheaterare all disposed within an interior area of said insulated cabinet. 7.The applicator system of claim 6 wherein the mixed material istransported from said static mixer to the applicator through a heatedhose connected to one end of said static mixer and to an inlet of saidapplicator.
 8. The applicator system of claim 6 wherein the second lineincludes a check valve to prevent the melted material from entering thesecond line.
 9. The applicator system of claim 6 wherein said mixingblock includes a check valve to prevent the second material fromentering said means for removing.
 10. The applicator system of claim 6wherein said preheater is a series of tubes in communication with eachother.
 11. An applicator system for melting, mixing and applying acomposition consisting of one or more materials, said applicator systemcomprising: a tank having a material receiving area; a heating systemsurrounding a majority portion of said tank to sufficiently melt amaterial disposed within the material receiving area; an insulatedcabinet receiving heat from said means for heating; means forcontrolling the amount of heat received within said insulated cabinet; apump and valve assembly in communication with said tank, said pumpremoving melted material from said tank; a proportioner, saidproportioner supplying a second material to the insulated cabinet and athird material; means for mixing the second material with the meltedmaterial; and an airless spray gun receiving the mixed second materialand melted material from said means for mixing and the third materialfrom said means for supplying; wherein said proportioner providingsupplying the second material and the third material in a predeterminedratio with respect to each other.
 12. The applicator system of claim 11wherein said means for mixing comprises: a preheater disposed withinsaid insulated cabinet, said preheater having an inlet and an outlet,said preheater communicating with said proportioner through a first lineconnected between the inlet of said preheater and a first outlet of saidproportioner; a mixing block in communication with said preheaterthrough a second line connected between the outlet of said preheater andan inlet of said mixing block, said mixing block also in communicationwith said means for removing, said mixing block receiving and mixing themelted material received from said mean for removing and the secondmaterial received through said preheater; and a static mixer incommunication with an outlet of said mixing block for transporting themixed material; wherein said pump and valve assembly, said static mixer,said mixing block and said preheater are all disposed within an interiorarea of said insulated cabinet; wherein the second line includes a checkvalve to prevent the melted material from entering the second line;wherein said mixing block includes a check valve to prevent the secondmaterial from entering said means for removing.
 13. The applicatorsystem of claim 12 wherein the mixed material is transported from saidstatic mixer to the applicator through a heated hose connected to oneend of said static mixer and to an inlet of said applicator.
 14. Theapplicator system of claim 13 wherein said preheater is a series oftubes in communication with each other.
 15. An applicator system formelting, mixing and applying a composition consisting of one or morematerials, said applicator system comprising: a tank having a materialreceiving area; means for heating said tank to sufficiently melt amaterial disposed within the material receiving area; a cabinetreceiving heat from said means for heating; means for removing meltedmaterial from said tank; means for supplying a second material and athird material; means for mixing the second material with the meltedmaterial; and an applicator receiving the mixed second material andmelted material from said means for mixing and the third material fromsaid means for supplying; wherein said means for supplying is aproportioner which supplies the second material and the third materialin a predetermined ratio.
 16. An applicator system for melting, mixingand applying a composition consisting of one or more materials, saidapplicator system comprising: a tank having a material receiving area;means for heating said tank to sufficiently melt a material disposedwithin the material receiving area; a cabinet receiving heat from saidmeans for heating; means for removing melted material from said tank;means for supplying a second material and a third material; means formixing the second material with the melted material; and an applicatorreceiving the mixed second material and melted material from said meansfor mixing and the third material from said means for supplying; whereinsaid means for mixing comprises: a preheater disposed within saidcabinet, said preheater having an inlet and an outlet, said preheatercommunicating with said proportioner through a first line connectedbetween the inlet of said preheater and a first outlet of saidproportioner; a mixing block in communication with said preheaterthrough a second line Connected between the outlet of said preheater andan inlet of said mixing block, said mixing block also in communicationwith said means for removing, said mixing block receiving and mixing themelted material received from said mean for removing and the secondmaterial received through said preheater; and a static mixer incommunication with an outlet of said mixing block for transporting themixed material; wherein said static mixer, said mixing block and saidpreheater are all disposed within an interior area of said cabinet. 17.The applicator system of claim 16 wherein the mixed material istransported from said static mixer to the applicator through a heatedhose connected to one end of said static mixer and to an inlet of saidapplicator.
 18. The applicator system of claim 16 wherein the secondline includes a check valve to prevent the melted material from enteringthe second line.
 19. The applicator system of claim 16 wherein saidmixing block includes a check valve to prevent the second material fromentering said means for removing.
 20. The applicator system of claim 16wherein said preheater is a series of tubes in communication with eachother.